Synthetic fabric having slip resistant properties and method of making same

ABSTRACT

A synthetic nonwoven fabric having bonded fibers forming channels surrounding unbonded fibers forming raised slip resistant spots. The fabric is made by extruding hot polymer through a spinneret die onto a moving belt to form a sheet of random fibers, which sheet undergoes a calendering process between a pair of heated rollers, one of which rollers having a plurality of cavities defined in its surface. The resulting fabric can be laminated and otherwise combined with other layers as desired to provide an end product having good slip resistant properties.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/706,137, filed Dec. 6, 2019, entitled SYNTHETIC FABRIC HAVING SLIPRESISTANT PROPERTIES AND METHOD OF MAKING SAME, which is a continuationof U.S. patent application Ser. No. 15/114,178, filed Jul. 26, 2016,entitled SYNTHETIC FABRIC HAVING SLIP RESISTANT PROPERTIES AND METHOD OFMAKING SAME, which claims the benefit of priority to InternationalPatent Application No. PCT/CA2015/050082, filed Feb. 4, 2015, entitledSYNTHETIC FABRIC HAVING SLIP RESISTANT PROPERTIES AND METHOD OF MAKINGSAME, which claims the benefit of priority to U.S. Provisional PatentApplication 61/935,797, filed Feb. 4, 2014, entitled SYNTHETIC FABRICHAVING SLIP RESISTANT PROPERTIES AND METHOD OF MAKING SAME, the entiredisclosures of which are incorporated herein by reference in theirentireties.

FIELD OF THE INVENTION

The present invention is in the field of roofing materials. Moreparticularly, the present invention is in the field of synthetic roofingmembrane materials having slip resistant characteristics so as toprovide suitable traction for roofing contractors during roofconstruction.

BACKGROUND OF THE INVENTION

The construction industry is a dangerous one for workers, with the mostfatal injuries of any industry in the private sector. Many of the risksand hazards are apparent, but they can be difficult to control. One areathat has received particular attention is the roofing industry, as oneof the leading causes of injury on a construction site is falls from aheight.

During roof construction, a roofing underlay is typically applied to theplywood roof prior to installation of shingles or tiles. Historicallythe roofing underlay was roofing felt or tar paper, both of which helpedin waterproofing roofs to prevent the ingress of moisture. Tar paper ismade by impregnating paper with tar, whereas roofing felt is impregnatedwith asphalt (bitumen). More recently, there has been a move tosynthetic underlay products. They provide a good water barrier and havebetter physical strengths as compared to roofing felts and tar paper.However, while synthetic products made out of various polymers havebetter performance characteristics, they are generally slippery.

Accordingly, the focus has been on developing synthetic roofing underlayproducts with good performance characteristics and that have goodanti-slip characteristics. There are two ways to enhance the slipresistance of the underlay products: “Mechanical” and “Chemical”. Thereare many products in the market with Chemical slip resistance; however,the problem with Chemical slip resistance is that as soon as you haveminute (0.5 mm) quantities of dust and/or frost on it, it gets coveredand does not work anymore.

For example, U.S. Pat. No. 6,296,912 teaches a roofing membrane materialcomprising a woven or nonwoven fibrous mat having an adhesive asphaltcoating.

U.S. Pat. No. 7,887,900 teaches a waterproofing roof underlay made ofone or more layers of flexible sheet material consisting of woven ornonwoven synthetic polymers of polypropylene with a skid resistantpattern of polymer elements made from a plasticized polyvinyl chloridedeposited on the top surface.

Efforts have also been made to develop a product with mechanicalresistance. For example, U.S. Pat. No. 6,925,766 teaches an underlaycomprising a flexible structural layer laminated to a mesh layer havinginterconnected reinforced strands and protruding nodes to provideincreased traction.

While there are a variety of products currently in the market forvarious weather conditions, they all have shortcomings in wet (rainy) orcold (frost) conditions. Accordingly, there remains a need for a roofingunderlay with good strength and water barrier characteristics that alsohas good anti-slip properties.

Objects of the invention will be apparent from the description thatfollows.

SUMMARY OF THE INVENTION

The invention consists of a synthetic roofing membrane material andmethod of manufacturing the same that provides a superior slip resistantsurface in dry, wet or frosty conditions. The focus of the presentinvention has been Mechanical slip resistance at the top side andchemical slip resistance at the bottom side. The mechanical slipresistance is achieved by the use of a unique nonwoven top surface thathas raised fibrous surfaces (random nonwoven fibers forming elevatedslip resistant spots separated by channels) that create a highcoefficient of friction (COF) when in contact with the footwear of theroofing membrane installer.

In one embodiment, the invention comprises a method of preparing anonwoven fabric comprising forcing a thermoplastic polymer resin througha spinerette die onto a moving belt to form a sheet made of randomlyoriented entangled fibers and then calendering the sheet between a pairof heated rolls, one of the heated rolls being an engraved roll with aplurality of cavities defined therein, to produce a calendered sheethaving a plurality of elevated portions comprised of random unbondedfibers, wherein adjacent ones of the plurality of elevated portionsbeing separated from one another by channels of bonded fibers.

Other aspects of the invention include one or more of the following:

-   -   the other one of the heated rolls being a smooth roll having a        smooth cylindrical outer surface;    -   the heated rolls are heated to a temperature and exert a        pressure on the sheet sufficient to form the channels of bonded        fibers and the elevated portions of unbonded fibers;    -   the engraved roll and the smooth roll being maintained at        different temperatures;    -   the engraved roll being maintained at a temperature between        142-146 degrees Celsius and the smooth roll being maintained at        a temperature between 137-140 degrees Celsius;    -   the cavities having a bottom surface at a depth greater than the        height of a top surface of the elevated portions above a top        surface of the channels such that an air pocket is formed        between the top surface of the elevated portions and the bottom        surface of the cavities during calendering of the sheet. The        height is greater than 0.5 mm;    -   adjacent cavities are separated by at least 0.5 mm;    -   the thermoplastic polymer resin comprises polypropylene,        polyethylene, polyester or nylon.

In another embodiment the invention comprises a method of making anonwoven fabric comprising forcing a resin through a spinerette die ontoa moving belt to form a sheet made of randomly oriented entangled fibersand calendering the sheet between a pair of heated rolls, one of therolls being engraved with a pattern of cavities that allow an air pocketbetween the surface of the cavity and the fibers of the nonwoven sheet;heating the rolls to a temperature and exerting a pressure such that thefibers within the cavities form elevated surfaces of slip resistantspots that consist of random unbonded fibers and fibers falling outsidethe cavities are in direct contact with the heated calender rolls andmelt sufficiently to form fused channels surrounding the elevatedsurfaces of unbonded fibers.

In another embodiment, the method further comprises laminating thecalendered sheet with a waterproofing layer. It can further comprise areinforcing scrim layer being laminated between the calendered sheet andthe waterproofing layer.

In a further embodiment, the invention comprises a roofing membranecomprising a nonwoven layer of randomly oriented entangled fibers, thenonwoven layer having a top surface comprising a plurality of elevatedportions having unbonded fibers, adjacent ones of the plurality ofelevated portions separated by channels of fused fibers, and having abottom surface of fused fibers; and a waterproofing layer laminated tothe bottom surface.

The roofing membrane may further comprise a scrim reinforcement layerlaminated between the nonwoven layer and waterproofing layer.

In a further embodiment, the invention comprises a nonwoven fabriccomprising a plurality of randomly oriented, entangled fibers forming asheet having a smooth bottom surface wherein said fibers are bonded andhaving a top surface comprising a plurality of elevated portions havingunbonded fibers, said elevated portions surrounded by channels of fusedfibers.

In another aspect, the fibers of the nonwoven fabric are formed fromthermoplastic polymer resin. The channels have a width of at least 0.5mm and the elevated portions have a top surface at least 0.5 mm abovethe channels.

The method further comprising air cooling the calendered sheet andpassing it over water cooled rollers prior to rolling it to form a jumboroll. The calendered sheet of nonwoven fabric can be further processedsuch as laminating it with a waterproofing membrane.

In another embodiment, the invention comprises a roofing membranecomprising a plurality of nonwoven fibers, said fibers bonded inportions to form depressed channels and portions of unbonded fibersforming elevated slip resistant surfaces.

In another embodiment, the invention comprises a roofing membranecomprising a nonwoven fabric comprising a plurality of nonwoven fibers,the fibers being bonded in portions to form depressed channels andunbonded in portions to form elevated slip resistant spots; and awaterproofing polyolefin layer laminated to the nonwoven fabric.

In another embodiment, the invention comprises a roofing membranecomprising a nonwoven fabric comprising a plurality of nonwoven fibers,the fibers being bonded in portions to form depressed channels andunbonded in portions to form elevated slip resistant spots; laminated toa reinforcing woven scrim layer which is laminated to a waterproofingpolyolefin bottom layer.

The foregoing was intended as a broad summary only and of only some ofthe aspects of the invention. It was not intended to define the limitsor requirements of the invention. Other aspects of the invention will beappreciated by reference to the detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the invention will become more apparent fromthe following description in which reference is made to the appendeddrawings and wherein:

FIG. 1 is a top view of a prior art nonwoven fabric with spot bonding.

FIG. 2 is a top view of a high spot nonwoven fabric according to thepresent invention.

FIG. 3 is a perspective view of the nonwoven high spot fabric of FIG. 2.

FIG. 4 is a top view of a nonwoven high spot fabric according to theinvention showing an alternate high spot shape and pattern.

FIG. 5 is a magnified photo of a nonwoven high spot fabric showing therandom web of unbonded fibers surrounded by channels of bonded fibers.

FIG. 6 is a schematic representation of a process for manufacturing thenonwoven high spot fabric of FIG. 2 .

FIG. 7 is a photograph of the roller used in the manufacture of thenonwoven high spot fabric of FIG. 2 .

FIG. 8 is a close up photograph showing a portion of the roller shown inFIG. 7 .

FIG. 9 is a cross-sectional view of a portion of the roller shown inFIG. 7 showing an engraved cavity in the roller.

FIG. 10 is a cross-sectional view of a roofing underlay incorporatingthe nonwoven high spot fabric according to the invention.

FIG. 11 is a cross-sectional view of a roofing underlay incorporatingthe nonwoven high spot fabric including a reinforcement scrim layeraccording to the invention.

FIG. 12 is a schematic representation of a process for laminating thenonwoven high spot fabric of the present invention to a substrate.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Nonwoven fabrics are commonly used in the manufacture of products,including roofing underlays. A regular nonwoven fabric is made byextruding a heated thermoplastic resin through a spinneret die unto amoving surface. The term “nonwoven” refers to the individual fiberswhich are randomly interlaid and entangled to form a web including amultitude of randomly distributed fibers. The web of fibers can bebonded to each other or unbonded. Known methods for bonding includethermal calendering, air bonding, and passing the web through asaturated steam chamber at an elevated pressure. Bonding by thermalcalendering is done by “spot bonding”, where one calender roll has aplurality of fine points which apply heat and pressure to the web tobond spots. FIG. 1 is a photograph of a nonwoven fabric shown with spotbonding as known in the art.

The present invention employs a novel calendering process to produce aspunbond nonwoven fabric 16 as shown in FIGS. 2 and 3 . The nonwovenfabric has a plurality of channels 18 and elevated portions in the formof raised grip or “high spots” 20 defined along its upper surface 22.The bottom surface (not shown) is comprised of bonded fibers and issubstantially smooth. The channels 18 are formed by compressed bondedfibers, with the grip or high spots comprising substantially unbondedfibers, especially at the upper surface 22. In FIG. 4 , a differentpattern is shown defined in the surface of the nonwoven fabric 116, withoval shaped slip resistant spots 120 in spaced separation from oneanother elevated above the bonded channels 118. FIG. 5 shows a close-upof the nonwoven fabric shown in FIG. 4 , with the unbonded, randomfibers 122 of the slip resistant spot 120 clearly visible. Of course,many different shapes and patterns for the slip resistant spots could beadopted, limited simply by ones imagination and the ability to form therequired shape and pattern in the calendering roll. Preferably, thenonwoven grip or “high spot” fabric is comprised of filaments formed ofpolypropylene (PP) resin; however, it is also contemplated that otherthermoplastic materials could be used, such as polyester, polyethylene,nylon and the like.

The elevated high spots in combination with the channels provide goodtraction even in wet conditions. Foreign material such as debris, dust,water and snow is diverted in the channels, leaving the high spots toprovide a gripping surface.

Production of the nonwoven high spot fabric is shown in FIG. 6 . Inorder to produce the nonwoven high spot fabric, the thermoplasticpolymer material (preferably PP resin) is heated until melted and theresulting molten material is extruded 30 through a spinneret die 31 toform long chains of fibers 32 that are sprayed onto a moving belt 34forming a sheet of nonwoven (randomly oriented, entangled) fibers. Therandom web of nonwoven fibers 32 passes through a calendering processusing our newly designed “high spot” cavity roller 36 and a standardroller 38. Cavity roller 36 is shown in FIGS. 7 and 8 , with across-sectional view of a portion in FIG. 9 . Cavity roller 36 is anengraved heated roller having a plurality of cavities 37 defined in itsouter circumferential surface 39. Standard roller 38 is simply a heatedroller with a smooth circumferential outer surface which generates thesmooth bonded bottom surface of the nonwoven fabric 16.

An example of suitable dimensions for a cavity roller are shown in FIG.9 . In the embodiment shown, the cavities 37 are recessed approximately1 mm into the surface of the roller and are 5 mm square at the deepestportion and approximately 6.1 mm at the surface. The cavities are spacedapproximately 1.5 mm from each other, meaning that the resultingchannels defined in the nonwoven fabric will be approximately 1.5 mm inwidth. Of course, other dimensions, shapes and patterns may be used,provided simply that the size of the recess in relation to the channelforming outer surface is controlled and that the depth of the cavity issufficient to create a small air pocket between it and the nonwovenfibers contained therein during the calendering process creating agreatly reduced heat transfer from the heated embossing roll to thenonwoven fibers so that the surface fibers remain unbonded.

As a further example, the oval “high spots” 120 shown in FIG. 4 havechannels that vary in width as a result of the nature of the oval shape.With this design, the channels are preferably at least 0.5 mm in width,with some portions (for example the junctions of three adjacent ovalspots) being much greater; for example, up to 1.5 to 2 mm.

Product thickness must be sufficient to create the key requirements ofthe product:

The high spots must be suitably elevated relative to the channels, inthe case of this example, preferably greater than 0.5 mm, and mostspecifically between 0.7 mm and 1 mm.

The top of the high spot must have non-bonded fibers to grip a roofer'sshoes.

Proper width of the channels, preferably greater than 0.5 mm.

The calendering process is carefully controlled to ensure that the topsurface of the high spots 20 remains a rough surface comprised of loose,unbonded fibers which create a slip resistant surface. While thepresence of a high spot with bonded fibers does provide some traction,it is the presence of the unbonded fibers that provides additionaltraction.

When commencing production, the sheet of fibers is hand fed from themoving belt 34 to the rollers 36 and 38. Once fed through the nip (thegap between the rollers 36 and 38) and fed around the remaining rollers,the process can proceed uninterrupted. Both rollers 36 and 38 areheated, however need not be heated to the same temperature. Thetemperature of the rollers is important in the overall process and canbe adjusted depending on the materials used and the thickness of theproduct. The rollers must be hot enough to ensure that the channel areais fused well, but not overheated. If overheated, the material will burnand lose its strength. For the product illustrated in FIG. 2 , thetemperature of roller 36 is preferably maintained between 142-146degrees Celsius, while the temperature of roller 38 is preferablymaintained between 137-140 degrees Celsius. The roller pressure is alsoimportant and must be adjusted depending on the thickness of the desiredproduct.

After passing between the calendering cavity roll 36 and the standardroll 38, the fabric sheet continues along a series of rollers and iswound in a Jumbo Roll form. When it first exits the calender rolls, thesheet is air cooled by adjusting the line speed to give the non-wovenenough time to cool down slightly then it is run over water cooledstainless steel rollers to ensure it is cooled and takes its final shapebefore winding it to form the Jumbo roll.

In order to provide a waterproofing layer, the nonwoven high spot fabricmust be bonded with a waterproofing membrane. These could form a numberof different combinations. For example, the high spot nonwoven can belaminated to a regular nonwoven, the lamination layer forming awaterproof barrier as discussed in more detail below. Such a combinationis illustrated in FIG. 10 , which shows the high spot nonwoven fabric16, lamination layer 42 and regular nonwoven 40 bonded together, withthe high spots 20, channels 18 and random fibers at the top 22 of thehigh spots 20 visible. Alternatively, the high spot nonwoven could belaminated to a woven scrim or a leno scrim and laminated to a bottombarrier layer such as with EVA, TPE, or EMA films, with Natural Kraft,with an asphalt or bitumen layer, or with other polyolefin or polymericlayers. Such a combination is illustrated in FIG. 11 , which shows thehigh spot nonwoven fabric 16, lamination layer 42, woven reinforcingscrim layer 43 and bottom barrier layer 47 bonded together, with thehigh spots 20, channels 18 and random fibers at the top 22 of the highspots 20 visible.

The lamination process consists of taking the high spot nonwoven andcombining it with another membrane material. FIG. 12 shows the standardlamination process for combining the high spot nonwoven fabric 16 withregular nonwoven 40. In this case, a high spot nonwoven 16 and a regularspot nonwoven 40 is fed into a lamination station where a hot laminationpolymer 42 is extruded through a lamination die 44 so as to besandwiched between the two nonwovens 16 and 40, which are forcedtogether as they travel through the nip between chill roll 46 and rubberroll 48. Nip pressures and winder tension should be adjusted to ensurethat the raised slip resistant spots are not flattened, with thefinished combination then wound on a paper core to form a Jumbo roll 50for further processing as necessary.

As discussed in more detail below, in the lamination process,temperature, pressure and cooling is controlled to achieve the bestphysical properties of the product and to ensure that the grip (“high”)spot pattern remains effective. The product is also trimmed to thedesired width prior to being wound on the paper core.

The product may also undergo further processing, such as a printingprocess in order to place product logo and other necessary informationon it. Once processing has been completed, the product goes through“rewinding”, where the Jumbo rolls are rewound into small 250 foot rollsand then packaged onto skids for shipping.

Additional manufacturing details are set out below.

Manufacturing Process

During production, the major focus was put on developing the “high spot”nonwoven manufacturing process, followed by the lamination process.Various trials were conducted as set out below.

Trial 1—Top Layer Nonwoven Thickness vs. Weight

A number of trials were conducted during which changes to the fiberdensity and weight were made. As the layer of nonwoven fibers passesthrough the calendering process, it is important that the cavities(inverted cups) 37 of the newly designed rollers 36 are not overfilled,as this would result in the creation of a solid surface. Accordingly, avariety of product weights were tested, from 150 grams per square meter(gsm) down to 50 gsm and the resulting effect on the non-slip surfaceand “angel hair” pattern (the random, unbonded fibers) was measured andobserved.

Trials were conducted by reducing the weight per square meter from 150gsm to 50 gsm in increments of 10 gsm. After running the variousincrements, it was determined that the heavier weights resulted in anend product that was too thick and expensive. Ultimately, four weightswere selected for producing standard end weight products (15 and 30 lb):50, 70, 80 & 90 gsm. These were tested with a slope tester and amagnifying glass to confirm the presence of sufficient unbonded fibersfor grip stop requirements.

Trial 2—Calendering Temperature

As the weight trials were completed, the temperature of the calendaringprocess was also adjusted to ensure fusion of the thermoplastic fibersonly occurs in the desired areas (the channels). If the temperature istoo high, the high spot area fibers fuse together creating a slipperysurface. Accordingly, trials were conducted for the calendaring processwith the cavity roll heated to temperatures between 150 degrees Celsiusto 130 degrees Celsius in increments of 2 degrees Celsius. After eachtest run, the bonding of the nonwoven fibers was observed in both thechannel and high spot areas. A temperature of 142 degrees Celsius wasobserved to be the best for the required weights, with a range ofapproximately 142-146. At this temperature, the high spots remainunfused (unbonded) and the channel area was fused to create the desiredpattern. In addition the bottom of the fabric is fused creating a smoothsurface.

Trial 3—Resin Blend & Melt Selection

Various trials were conducted for the polypropylene melt flowproperties. Polypropylene resin was selected from 22 MI to 35 MI for thetrials. High melt flow resins are easier to process but produce a lowerstrength fiber. Testing started with a 35 MI resin which produced a goodeven profile fiber, but a lower strength fabric. Finally, a 25 MIpolypropylene resin was selected in combination with 2% UV stabilizermasterbatch and 2% color additive to create an even flow and evenprofile of high spun nonwoven fabric. It was found that a higher colourratio also tends to change the material flow and consequently thephysical appearance and evenness of the resulting nonwoven fabric. Acolour ratio of 1.5 to 2.5% was found to work best with the blend toproduce the desired results.

Trial 4—Manufacturing Speed and Winding Tension

Various trials were conducted to ensure a stable process is maintainedto achieve the right grip spot structure. Higher speeds resulted in warmfabric being wound with a resulting distortion to the high spotstructure. Line speed trials from 80 to 40 meters per minute wereconducted. As a result of these trials, it was determined that a linespeed of 45-55 meters per minute produced satisfactory results alongwith the parameters determined from the first 3 trials discussed above.

The winding tension was also reduced to ensure the rolls were not woundtoo tight such that the high spots were flattened. Once the fabric coolsdown sufficiently and takes its final shape, the winding tension orpressure does not seem to affect the grip spots. Lower line speed alsocreates better annealing time for the nonwoven to settle in its desireddesign.

Lamination Process

The lamination process is critical to ensure the final product hassuitable water proofing characteristics. The lamination process takestwo separate nonwovens (one regular and one high spot) and laminatesthem together with the lamination layer acting as a water barrier. TypeI products contain a mono lamination layer & Type II products containtwo separate layers of polymer for lamination and antiskid properties.For example, for a type II product, the nonwoven high spot fabric 16 waslaminated to a scrim and then an antiskid film was laminated to it.

The following trials were conducted to ensure the final product had thedesired characteristics.

1. Product Blends

The product blends were optimized to ensure good lamination, waterbarrier properties, pliability, and softness for installation. Theobvious choice for the lamination layer was polypropylene as thenonwoven fabrics are made of polypropylene. However, 100% polypropyleneused for lamination created a very stiff and hard to work product. A lowdensity polyethylene was added in increments of 5% up to 30%. At 30%some poor lamination effects were observed and it was reduced to 25%where good lamination was achieved with a resulting softer, and easierto work with, product. Water ponding and rain tests were conducted toensure the product has suitable water barrier properties. A 2% UVadditive was added to ensure UV stability of the product.

2. Process Parameter Optimization

A temperature profile was created for the above blend to maximizelamination and reduce degradation of the polymer. A high temperatureresults in higher polymer flow, which in turn results in penetration ofthe polymer through the nonwoven creating a slippery surface and poorwater barrier properties. A temperature range of 260-265 degrees Celsiuswas established to ensure the desired physical and barrier properties ofthe fabric.

3. NIP Pressure

Along with resin blend and temperature of extrudate, the NIP pressureplays an important role. Higher NIP pressure will damage the high spotsurface, impregnate laminate polymer into the nonwoven layers, andcreate an uneven lamination film layer, which in turn can damage thewater barrier properties of the product. Trials were conducted from 90PSI down to 30 PSI on Nip rollers of laminate. It was determined that arange of 40-50 PSI performed the best for lamination and film integrity.Both water ponding and rain tests were conducted to ensure the desiredphysical outcome. The NIP rollers selected for this process were a steel“chill” roller and a silicone “rubber” roller with greater than 60durometer hardness to achieve the best results.

It is contemplated that the high spot non woven product produced withour new cavity calendar roll can be used in more than just roofingapplications. For example, it could be used as a housewrap, as abreathable underlayer should this be desired, or as a house envelopedmembrane.

As discussed above, the high spot nonwoven can be combined with aplurality of different types of membrane layers depending on the desiredcharacteristics for the end product. For example, the high spot nonwovencould be laminated to an antislip film with a lamination layer ofpolypropylene or polyethylene, or it could be coated directly with anantislip coating to improve the back side (bottom surface) slipresistance. A further example would be the type II product discussedabove where the high spot nonwoven is laminated to a woven scrim(preferably formed of polyethylene or polypropylene) with a laminationlayer of polyethylene or polypropylene. If desired, the back side of thewoven scrim may be further coated with an antislip/antiskid coating.

It will be readily appreciated by those skilled in the art that variousmodifications and variations of the present invention may be devisedwithout departing from the scope or spirit of the invention

The invention claimed is:
 1. A system, comprising: a roof deck; aplurality of roofing shingles; and a roofing membrane installed abovethe roof deck, wherein the roofing membrane comprises: a calenderedsheet; a resin lamination layer; and a scrim layer; and wherein thecalendered sheet comprises a polymer resin; wherein the calendered sheetcomprises:  a) a plurality of elevated portions of random unbondedfibers, and  b) bonded fibers in channels between the plurality ofelevated portions; wherein the resin lamination layer:  a) is betweenthe calendered sheet and scrim layer, and  b) extends at least from afirst end of the calendered sheet to a second end of the calenderedsheet opposite the first end, and wherein the scrim layer extends atleast from the first end of the calendered sheet to the second end ofthe calendered sheet, wherein the roofing membrane is between theplurality of roofing shingles and the roof deck.
 2. The system of claim1, wherein the polymer resin comprises polypropylene, polyethylene,polyester, or nylon.
 3. The system of claim 1, wherein the scrim layercomprises a woven material.
 4. The system of claim 3, wherein the wovenmaterial comprises at least one of polyethylene or polypropylene.
 5. Thesystem of claim 1, wherein the resin lamination layer comprises apolymer.
 6. The system of claim 1, wherein the resin lamination layercomprises: between 5% and 30% low-density polyethylene, andpolypropylene.
 7. The system of claim 1, wherein the roofing membranefurther comprises: a resin coating layer, wherein the resin coatinglayer is on the scrim layer, and extends at least from the first end ofthe calendered sheet to the second end of the calendered sheet.
 8. Thesystem of claim 7, wherein the resin coating layer comprises a film. 9.The system of claim 8, wherein the film comprises at least one ofpolyethylene and polypropylene.
 10. The system of claim 1, wherein theresin lamination layer comprises polyethylene and polypropylene.
 11. Asystem, comprising: a roof deck; at least one roofing shingle; and aroofing membrane, wherein the roofing membrane comprises: a calenderedsheet; a resin lamination layer; and a scrim layer; and wherein thecalendered sheet comprises a resin; wherein the calendered sheetcomprises:  a plurality of elevated portions of random unbonded fibers,and  bonded fibers in channels between the plurality of elevatedportions; wherein the resin lamination layer:  is between the calenderedsheet and scrim layer, and extends at least from a first end of thecalendered sheet to a second end of the calendered sheet opposite thefirst end, and wherein the scrim layer extends at least from the firstend of the calendered sheet to the second end of the calendered sheet,wherein the roofing membrane is between the at least one roofing shingleand the roof deck.
 12. The system of claim 11, wherein the resincomprises polypropylene, polyethylene, polyester, or nylon.
 13. Thesystem of claim 11, wherein the scrim layer comprises a woven material.14. The system of claim 13, wherein the woven material comprises atleast one of polyethylene or polypropylene.
 15. The system of claim 11,wherein the resin lamination layer comprises a polymer.
 16. The systemof claim 11, wherein the resin lamination layer comprises: between 5%and 30% low-density polyethylene, and polypropylene.
 17. The system ofclaim 11, wherein the roofing membrane further comprises: a resincoating layer, wherein the resin coating layer is on the scrim layer,and extends at least from the first end of the calendered sheet to thesecond end of the calendered sheet.
 18. The system of claim 17, whereinthe resin coating layer comprises a film.
 19. The system of claim 18,wherein the film comprises at least one of polyethylene andpolypropylene.
 20. The system of claim 11, wherein the resin laminationlayer comprises polyethylene and polypropylene.